Reclosable Bag

ABSTRACT

A reclosable bag for storing edibles is provided and includes a body having an inner surface defining an inner volume that receives the edibles and an outer surface formed on an opposite side of the body than the inner surface. A seal extends substantially parallel to a longitudinal axis of the body and is formed by joining a first portion of the inner surface to a second portion of the inner surface. A deadfold material is disposed in the seal between the first portion of the inner surface and the second portion of the inner surface, is formed from a malleable material, and is retained in position along the body by the seal.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional application No. 62/134,837, filed on Mar. 18, 2015. The entire contents of the aforementioned application are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

This disclosure relates to reclosable bags.

BACKGROUND

Many edibles (e.g., cereal, candy, chocolate, dried fruits, chips, cookies, or other food products) are sold in bags. Some edibles such as cereal are stored in a bag and the bag is placed inside a box (e.g., a cereal box). Most food manufacturers and retailers sell edibles in bags that are sealed. In some examples, the seal prevents moisture from entering the bag. In other examples, the seal prevents undesirable objects from entering the bag (e.g., dust, insects, etc.) In yet other examples, the seal extends the life of the edibles or prevents the edibles from spoiling. However, once a consumer opens the seal of a bag, the edibles inside the bag are at risk of being exposed to moisture and being spoiled. Therefore, there is a need for a reclosable bag that prevents moisture and other undesirable objects from entering the bag after the consumer breaks the seal of the bag.

SUMMARY

In one configuration, a reclosable bag for storing edibles is provided and includes a body having an inner surface defining an inner volume that receives the edibles and an outer surface formed on an opposite side of the body than the inner surface. A seal extends substantially parallel to a longitudinal axis of the body and is formed by joining a first portion of the inner surface to a second portion of the inner surface. A deadfold material is disposed in the seal between the first portion of the inner surface and the second portion of the inner surface, is formed from a malleable material, and is retained in position along the body by the seal.

In one configuration, the deadfold material includes a first element and a second element, whereby the first element and the second element are spaced apart from one another by a gap extending in a first direction substantially perpendicular to the longitudinal axis. In this configuration, the first portion of the inner surface and the second portion of the inner surface may be attached to one another within the gap. Alternatively, the first portion of the inner surface and the second portion of the inner surface may be spaced apart from one another within the gap such that the first element and the second element oppose one another within the gap. Regardless of the particular construction of the reclosable bag, the gap may be about 1 mm to about 5 mm in the first direction.

In one configuration, the first element is formed from metal and the second element is formed from metal. Further, the seal is formed by welding the first portion of the inner surface to the second portion of the inner surface at a first location along the first element and at a second location along the second element. The seal may additionally be formed by welding the first portion of the inner surface to the second portion of the inner surface at a third location within the gap, whereby the first location, the second location, and the third location extend along an entire length of the first element and the second element in a direction substantially parallel to the longitudinal axis. The first portion of the inner surface and the second portion of the inner surface may be ultrasonically welded to one another at the first location, the second location, and the third location.

A method of manufacturing a reclosable bag is also provided and includes forming a sheet of material having a first surface and a second surface disposed on an opposite side of the sheet of material than the first surface into a body having a substantially cylindrical shape. The method further includes aligning a first longitudinal edge of the sheet with a second longitudinal edge of the sheet such that a first portion of the first surface opposes a second portion of the first surface. A deadfold material is positioned between the first portion of the first surface and the second portion of the first surface. The first portion of the first surface is attached to the second portion of the first surface to retain the deadfold material between the first portion and the second portion.

In one configuration, attaching the first portion to the second portion includes ultrasonically welding the first portion to the second portion.

In one configuration, positioning the deadfold material includes positioning a first element and a second element between the first portion and the second portion. A longitudinal axis of the first element and a longitudinal axis of the second element are aligned with a longitudinal axis of the body such that all three of the axes are substantially parallel to one another.

In one configuration, attaching the first portion of the first surface to the second portion of the first surface includes attaching the first portion to the second portion at a first location along an entire length of and adjacent to the first element and at a second location along an entire length of and adjacent to the second element. Attaching the first portion of the first surface to the second portion of the first surface may additionally include attaching the first portion to the second portion at a third location between the first element and the second element.

In one configuration, attaching the first portion to the second portion at the third location includes attaching the first portion to the second portion along an entire length of the first element and the second element. Attaching the first portion to the second portion at the first location, the second location, and the third location may include ultrasonically welding the first portion to the second portion at the first location, the second location, and the third location.

In one configuration, positioning the deadfold material between the first portion of the first surface and the second portion of the first surface includes positioning a malleable material between the first portion and the second portion. Further, a first end of the cylindrical body and a second end of the cylindrical body may be sealed, whereby the first end and the second end extend substantially perpendicular to the first longitudinal edge and the second longitudinal edge.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of an exemplary reclosable bag for storing edibles.

FIG. 1A is a perspective view of a box with an exemplary reclosable bag for storing edibles.

FIG. 1B is a perspective view of the box with the reclosable bag of FIG. 1A storing edibles.

FIG. 1C is a perspective view of the box with the reclosable bag of FIG. 1B folded and storing edibles.

FIG. 2 is a perspective view of the reclosable bag shown in FIG. 1.

FIGS. 3A-3C are plan views of different implementations of a reclosable bag.

FIGS. 4A-4C are plan views of different implementations of a reclosable bag.

FIG. 4D is a plan view a reclosable bag in a folded position.

FIGS. 5A is a perspective view of an exemplary reclosable bag for storing edibles.

FIGS. 5B-5E are cross-sectional views of different implementations of deadfold materials of FIG. 5A.

FIG. 5F is a perspective view of an exemplary reclosable bag for storing edibles.

FIG. 6 is a schematic view of an example arrangement of operations for manufacturing a reclosable bag.

FIG. 7A is a perspective view of an exemplary rectangular sheet.

FIGS. 7B-7F are perspective views of an exemplary bag body formed from the rectangular sheet of FIG. 7A based on the process of FIG. 6.

FIG. 8 is another example arrangement of operations for manufacturing the reclosable bag.

FIGS. 9A-9D are perspective views of an exemplary bag body formed based on the process of FIG. 8.

FIG. 10A is a perspective view of a vertical form, fill, and seal (VFFS) system used to form a reclosable bag in accordance with the principles of the present disclosure.

FIG. 10B is a partial perspective view of the VFFS system of FIG. 10A showing a feeding system that provides a deadfold material when forming the reclosable bag.

FIG. 10C is a partial perspective view of the feeding system of FIG. 10B showing a cutting device used to segment the deadfold material and an ultrasonic welding system.

FIG. 10D is a partial perspective view of the cutting device and ultrasonic welding system of FIG. 10C in use showing the cutting device severing a portion of the deadfold material and the ultrasonic welding system securing the deadfold material between layers of a bag material.

FIG. 10E is a perspective view of a partially formed bag being cut and sealed at a lower end thereof.

FIG. 10F is a perspective view of the partially formed bag of FIG. 10E being cut and sealed at an upper end thereof.

FIG. 10G is a perspective view of a fully formed bag that is severed from an adjacent bag.

Like reference symbols and the various drawings indicate like elements.

DETAILED DESCRIPTION

FIGS. 1A-1C illustrate an example box 10 that may be used to store edibles 50. In some examples, the box 10 is a cereal box 10 c and the edibles 50 include cereal 50 c. The box 10 includes a reclosable bag 100 (e.g., FIG. 1), such as a cereal bag 100 that stores cereal 50 c. The bag 100 may include a tubular body 110 (also referred to as a bag body). The bag body 110 includes a first end 112 and an opposite, second end 114. In the examples shown in FIGS. 1A-1C, the first end 112 is sealed to form a closed bottom of the bag 100. A manufacturer of the edibles 50 may also seal the second end 114 of the bag body 110 to contain the edibles 50 within the bag 100 and to avoid the edibles 50 from spilling outside the bag 100.

The bag 100 further includes a seal 130 that maintains the structural integrity of the bag body 110. In some examples, a press may bind opposite edge portions of a rectangular sheet to form the bag body 110. The seal 130 extends from the first end 112 of the bag body 110 to the second end 114 of the bag body 110. A foldable deadfold material 150 is embedded in the seal 130. When the deadfold material 150 is folded, the deadfold material 150 retains its folded shape, thereby allowing the bag body 110 to remain folded as well.

Once a consumer purchases the box 10, the consumer may break the seal of the second end 114 of the bag body 110 to access the edibles 50. If the bag 100 is not reclosed properly, moisture 80 may enter the bag 100 and spoil the edibles 50. Further, the moisture 80 may diminish the taste or nutritional value of the edibles 50. For example, the moisture 80 may make the cereal 50 c less crunchy than desirable. Another negative consequence of not closing the bag 100 properly is that debris or an insect 82 may enter the bag 100.

The deadfold material 150 allows the consumer to reclose the bag 100 even after the consumer has broken the seal at the second end 114. As shown in FIG. 1C, the consumer can reclose the bag 100 by folding the deadfold material 150. Because the deadfold material 150 is attached to the bag body 110 of the bag 100, the bag body 110 remains folded when the deadfold material 150 is folded. By folding the bag body 110 along a length L_(D) of the deadfold material 150, the bag 100 can be reclosed. Reclosing the bag 100 reduces the likelihood of moisture 80 or other debris 82 entering the bag 100.

Although in the example of FIGS. 1B and 1C the box 10 and the reclosable bag 100 store edibles 50, in other examples the box 10 and the reclosable bag 100 may store other objects. For example, the reclosable bag 100 may be used to store non-edibles such as books, papers or other effects that may need protection from moisture, dust or other foreign particles. Further, in the example of FIGS. 1B and 1C, the bag 100 is transparent. However, in other examples, the bag 100 may be translucent or opaque. For example, a translucent or opaque bag 100 may be used to protect objects that are sensitive to light. In some examples, the bag 100 may be constructed from material that can shield an object from certain electromagnetic radiation and the bag 100 may be used to store objects that are susceptible to electromagnetic radiation (e.g., film, credit cards, or mobile electronic devices with Near Field Communications chips).

Referring to FIG. 2, the bag body 110 has a length L_(B) defined as a distance between the first end 112 and the second end 114 of the bag body 110. The seal 130 extends between the sealed first end 112 and the second open end 114 of the bag body 110 and in the example of FIG. 2, abuts the first end 112 and the second end 114. However, in other examples the seal 130 may extend between the first open end 112 and the second sealed end 114, but does not abut the sealed first end 112 and/or the second open end 114.

The deadfold material 150 is disposed in the seal 130. The deadfold material 150 can be folded along a length L_(D) of the deadfold material 150. When the deadfold material 150 is folded along its length L_(D), the deadfold material 150 retains its folded shape, thus allowing the bag body 110 to remain folded when the deadfold material 150 is folded. Because the bag body 110 remains folded when the deadfold material 150 is folded, the reclosable bag 100 can be closed to prevent moisture 80 from entering the reclosable bag 100. Being able to close the reclosable bag 100 after removing some edibles 50 from the bag 100 allows the remaining edibles 50 (or any other items stored in the reclosable bag 100) to remain relatively moisture free. Further, being able to fold the bag body 110 and close the reclosable bag 100 may extend the life of the edibles 50.

Referring to FIG. 3A, in some implementations, the seal 130 has a length L_(S) that is substantially equal to the bag body length L_(B). The deadfold material 150 has a first end portion 152 and a second end portion 154 and a length L_(D) defined as a distance between the first end portion 152 and the second end portion 154. The deadfold material 150 is positioned such that the first end portion 152 of the deadfold material 150 is a first distance D₁ from the first end 112 of the bag body 110. Further, the second end portion 154 of the deadfold material 150 is a second distance D₂ from the second end 114 of the bag body 110. In the example of FIG. 3A, the seal length L_(S) is substantially equal to the bag body length L_(B). In the examples of FIGS. 3B and 3C, however, the seal length L_(S) is different from the bag body length L_(B). In the example of FIG. 3B, the seal 130 has a seal length L_(S) less than the bag body length L_(B), but greater than the deadfold length L_(D). In the example of FIG. 3C, the seal 130 has a seal length L_(S) approximately or substantially equal to the deadfold length L_(D).

Referring again to FIG. 3A, in some implementations, the seal 130 holds the tubular bag body 110 intact. For example, the bag body 110 may be formed by sealing two opposite edges 710 of a rectangular sheet 700 (FIG. 7A), where the seal 130 holds the two opposite edges 710 of the rectangular sheet 700 together to form the substantially rectangular body 110. By contrast, in other implementations, the tubular bag body 110 may be formed and held intact without the seal 130. In the example of FIG. 3C, the bag body 110 is formed from a single and continuous piece of material, so that the seal 130 is not required to hold the bag body 110 intact. However, in the example of FIG. 3C, the seal 130 holds the deadfold material 150 in place. The deadfold material 150 may be embedded in the seal 130 such that the deadfold material 150 is encapsulated by the seal 130 (i.e., by the material of the sheet 700 when the seal 130 is formed).

In the examples of FIGS. 3A-3C, the second distance D₂ is less than the first distance D₁, which allows the deadfold material 150 to be positioned near the open second end 114 of the bag body 110. When the deadfold material 150 is positioned towards the open second end 114 and away from the closed first end 112 of the bag body 110, the deadfold material 150 can be folded to close the reclosable bag 100 regardless of the amount of edibles 50 stored inside the bag 100. In those examples, the length L_(D) of the deadfold material 150 is less than the bag body length L_(B). Moreover, when the deadfold length L_(D) is less than the bag body length L_(B), the deadfold material 150 only extends along a portion of the bag body 110 and not the entire length L_(B) of the bag body 110.

As shown in FIGS. 3A-3C, in some implementations, the deadfold material 150 only extends near the open second end 114 of the bag body 110 and not the sealed first end 112 of the bag body 110. Using the deadfold material 150 can increase the cost of the reclosable bag 100. Accordingly, extending the deadfold material 150 along only a portion of the bag body 110 minimizes the increase in cost. Further, the deadfold material 150 may extend only along a portion of the entire length L_(B) of the bag body 110 typically folded by a user. For example, if the deadfold material 150 extends from the first sealed end 112 to the open second end 114 of the bag body 110, the portion of the deadfold material 150 immediately proximate to the ends 112, 114 may not be routinely utilized. The deadfold material 150 abutting the sealed first end 112 may rarely be folded, because there would be no edibles stored towards that end of the bag 100. Similarly, deadfold material 150 disposed proximate to the open second end 114 of the bag body 110 may rarely be folded because the bag 100 is not usually filled with edibles 50 proximate to the open second end 114.

FIGS. 4A-4C show different implementations of the reclosable bag 100. In each implementation shown, the deadfold material 150 has a deadfold length L_(D) less than the bag body length L_(B) and less than the seal length L_(S). Because the deadfold material 150 does not extend along the entire bag body length L_(B), a costs associated with manufacturing the reclosable bag 100 are reduced when compared to a bag having deadfold material 150 extending along the entire length of the bag 100. The deadfold material 150 does not extend along the second distance D₂, because it is unlikely that edibles 50 will be placed in such close proximity to the open second end 114 of the reclosable bag 100. The bag 100 shown in FIG. 4B has a deadfold material 150 with a second deadfold length L_(D2) longer than a first deadfold length L_(D1) shown in FIG. 4A, but shorter than a third deadfold length L_(D3) shown in FIG. 4C. The bag 100 may be configured with a deadfold length L_(D), L_(D1), L_(D2), L_(D3) appropriate for a given usage of the bag 100. A longer deadfold material 150 allows for more folding of the deadfold material 150 along the length L_(B) of the bag body 110. As shown, the second distance D₂ being the distance between the deadfold material 150 and the open second end 114 is shorter than the first distance D₂ being the distance between the deadfold material 150 and the sealed first end 112. A shorter second distance D₂ allows the deadfold material 150 to be folded in closer proximity to the first sealed end 112, thereby reducing the amount of air that may be trapped in the reclosable bag 100 when the reclosable bag 100 is reclosed.

In the example of FIG. 4C, the deadfold material 150 has a longer deadfold length L_(D3) than the examples of FIGS. 4A and 4B. The second distance D₂ of FIG. 4C is also shorter than the first distance D₁, thereby allowing the deadfold material 150 to be folded closer to the sealed first end 112 of the reclosable bag 100. This further reduces the amount of air that may get trapped in the reclosable bag 100 when the deadfold material 150 is folded and the amount of edibles 50, 50 c disposed within the bag 100 is minimal (i.e., when a majority of the edibles 50, 50 c have been removed from the bag 100).

The second distance D₂ may be further shortened. The shorter the second distance D₂ is, the tighter a user can reclose the bag 100 when there is a large amount of edibles within the reclosable bag body 110. However, a shortened second distance D₂ will increase the cost of the reclosable bag 100 due to use of a longer length of the deadfold material 150.

FIG. 4D illustrates the reclosable bag 100 in a folded position. In the folded position, the bag body 110 is folded at a folded region 150 f of the deadfold material 150. The bag body 110 includes a folded portion 110 f and an unfolded portion 110 u. The folded portion 110 f has a folded length L_(F) and the unfolded portion 110 u has an unfolded length L_(U). The unfolded length L_(U) is defined as a distance between the closed first end 112 and the folded region 150 f. The folded length L_(F) is defined as a distance between the open second end 114 and the folded region 150 f.

The deadfold material 150 includes a first end portion 150 a and a second end portion 150 b. The second end portion 150 b of the deadfold material 150 is near the open second end 114 of the bag body 110; the first end portion 150 a is further away from the open second end 114. When the bag body 110 is folded at the folded region 150 f near the first end portion 150 a, the second end 114 of the bag body 110 is placed in proximity to the first end 112. In some implementations, the unfolded length L_(U) is greater than one-half of the body length L_(B) (L_(U)>0.5 L_(B)) and the folded length L_(F) is less than one-half of the body length L_(B) (L_(F)>0.5 L_(B)). The unfolded length L_(U) may be less than, equal to, or greater than the folded length L_(F), depending on where a user folds the reclosable bag 100.

The bag 100 may reside within a box 10. A first end 10 a (e.g., a bottom) of the box 10 may support the sealed first end 112 of the bag 100. A second end 10 b (e.g., a top) of the box 10 may be open to provide access to the bag 100 (e.g., the open second end 114). In some implementations, when the bag 100 is in the folded position, the sealed first end 112 of the bag 100 touches the second end 10 b of the box 10 but the open second end 114 does not touch the second end 10 b of the box 10. If the folded length L_(F) is greater than the unfolded length L_(U), a portion of the folded portion 110 f may need to be folded around the unfolded portion 110 u of the bag body 110. Therefore, when the folded length L_(F) is less than the unfolded length L_(U), an additional fold may be avoided; however, when the folded length L_(F) is greater than the unfolded length L_(U), an additional fold (or more) may be needed in the folded portion 110 f to tighten the enclosure of the bag 100.

FIGS. 5B-5E illustrate cross sectional views of different examples of the deadfold material 150 of the reclosable bag 100 of FIG. 5A incorporated into the bag body 110. As previously described, the bag body 110 includes a seal 130 having a first layer 132 and a second layer 134. The deadfold material 150 is embedded between the first layer 132 and the second layer 134 of the seal 130. In the example of FIG. 5B, the deadfold material 150 includes a metallic strip 170 disposed along the seal 130. The metallic strip 170 is malleable so that the metallic strip 170 is foldable. When the metallic strip 170 is folded, the metallic strip 170 maintains its folded position and causes the bag body 110 to remain folded.

FIG. 5C illustrates another example of the deadfold material 150. In this example (FIG. 5C), the deadfold material 150 includes a metal wire 172 extending along the length L_(D) of the deadfold material 150. The metal wire 172 is embedded between the first layer 132 and the second layer 134 of the seal 130 and includes a longitudinal axis (2) that extends substantially parallel to a longitudinal axis of the bag 100. The metal wire 172 uses less material than the metallic strip 170 of FIG. 5B, which may be more cost efficient than using the metallic strip 170 of FIG. 5B.

FIG. 5D illustrates another example of the deadfold material 150. The deadfold material 150 includes a first metal wire 172 a and a second metal wire 172 b that extend along the length L_(D) of the deadfold material 150 and are separated by a gap 174. The separation gap 174 may be about 1 to 5 millimeters. In some examples, the gap 174 may be about two (2) millimeters. Other measurements of the separation gap 174 are also possible and may depend on the length L_(B) of the reclosable bag 100 and/or the length L_(D) of the deadfold material 150.

FIG. 5E illustrates yet another example of the deadfold material 150. The deadfold material 150 includes a first metal wire 172 a, a second metal wire 172 b, and a third metal wire 172 c. Each metal wire 172 a, 172 b, 172 c is separated by a gap 174, as shown in FIG. 5D. The first and second metal wires 172 a, 172 b are separated by a first gap 174 a, and the second and third metal wires 172 b, 172 c are separated by a second gap 174 b, as shown in FIG. 5E. The example of FIG. 5E includes three metal wires, which provide structural stability and rigidity to the deadfold material 150.

The gaps 174 and 174 a are shown as being open such that the first layer 132 and the second layer 134 are spaced apart from one another along the length of each gap 174, 174 a. The gap 174 b is shown with the first layer 132 being attached to the second layer 134 along a length of the gap 174 b such that the adjacent wires 172 b, 172 c are separated from one another in the location of the gap 174 b by the joined layers 132, 134 that form the seal 130. The layers 132, 134 may be joined by ultrasonically welding the layers 132, 134 together in the area of the gap 174 b when forming the seal 130, as will be described below. While the gaps 174, 174 a are shown as being open and the gap 174 b is shown as being closed, all of the gaps 174, 174 a, and 174 b may be closed or, alternatively, all of the gaps 174, 174 a, and 174 b may be open. Further, any configuration of open gaps and closed gaps may be used. For example, each of gaps 174 a, 174 b may be open or closed or, alternatively, one of the gaps 174 a, 174 b may be open while the other gap 174 a, 174 b is closed.

In the examples of FIGS. 5A to 5E the first layer 132 and the second layer 134 are ultrasonically welded. Ultrasonic welding is a welding technique where high-frequency ultrasonic acoustic vibrations are applied to the workpieces (e.g., the first and second layers 132, 134 of the seal 130) under pressure to create a solid-state weld. Ultrasonic welding does not use any connective bolts, nails, soldering materials, or adhesives to bind the working pieces together. By ultrasonically welding the first layer 132 to the second layer 134, an adhesive is not needed to hold the deadfold material 150 in place between the first and second layers 132, 134. Therefore, ultrasonically welding the first layer 132 to the second layer 134 is a cost efficient way of securing the deadfold material 150 compared to using an adhesive to secure the deadfold material 150 to the bag body 110.

While the seal 130 is shown in FIG. 5A as being positioned along a middle portion of the reclosable bag 100, the seal 130 and, thus, the deadfold material 150 could alternatively be located at an outer edge or corner of the bag 100. For example, the seal 130 and deadfold material 150 may be located at a corner of the bag 100, as shown in FIG. 5F in an effort to maintain a back panel of the bag 100 free from interruption (i.e., caused by the raised seal 130 and deadfold material 150). Maintaining the back panel of the bag 100 free from interruption allows the back panel to be used for advertisement, product identification, nutritional information, and/or other information relating to the contents of the bag 100.

Any of the configurations shown in FIGS. 5B-5E could be used in conjunction with the bag 100 shown in FIG. 5F. For example, the two-wire configuration shown in FIG. 5D could be placed at the location shown in FIG. 5F to provide the seal 130 and the deadfold material 150 at a location that is spaced apart and separated from a central location of the back panel of the bag 100.

Ultrasonic welding equipment can be customized to fit the exact specifications of the parts being welded. The parts (e.g., the longitudinal edge portions 710) are sandwiched between a fixed shaped nest (anvil) and a sonotrode (horn) connected to a transducer. The transducer emits approximately a 20 kHz low-amplitude acoustic vibration. Common frequencies used in ultrasonic welding of thermoplastics are 15 kHz, 20 kHz, 30 kHz, 35 kHz, 40 kHz, and 70 kHz. When welding plastics, the interface of the two parts is specially designed to concentrate the melting process. One of the materials usually has a spiked energy director that contacts the second plastic part. The ultrasonic energy melts the point contact between the parts, creating a joint (e.g., seal 130). This process is a good automated alternative to glue, screws, or snap-fit designs.

An ultrasonic welding system may include: a press to put the two parts to be assembled under pressure; a nest or anvil where the parts are placed and that allows the high frequency vibration to be directed to the interfaces; and an ultrasonic stack composed of a converter or piezoelectric transducer, an optional booster, and a sonotrode. All three elements of the stack may be specifically tuned to resonate at the same ultrasonic frequency (Typically 20, 30, 35 or 40 kHz). The ultrasonic welding system may also include: a converter that converts the electrical signal into a mechanical vibration; a booster that modifies the amplitude of the vibration; a sonotrode that applies the mechanical vibration to the parts to be welded; an electronic ultrasonic generator or power supply that delivers a high power AC signal with a frequency that may match the resonance frequency of the stack; and a controller controlling the movement of the press and the delivery of the ultrasonic energy.

Some ultrasonic welding systems may include fewer or additional components. For example, some controllers may not control the movement of the press and may instead rely on a machine operator to control the movement of the press.

With reference to FIGS. 10A-10G, an exemplary vertical form, fill, and seal (VFFS) system 500 for use in forming the reclosable bag 100 is provided. The VFFS system 500 includes a fill tube 502, a sealing mechanism 504, film transport belts 506, cross-sealing jaws 508, and a deadfold feeding system 510. The VFFS system 500 receives the sheet of material 700 proximate to a top portion of the fill tube 502 and causes the flat sheet 700 to take a substantially cylindrical shape that encircles the fill tube 502. Accordingly, the fill tube 502 extends through the sheet of material 700 during formation of the reclosable bag 100 to allow the fill tube 502 to be in communication with an interior of the reclosable bag 100 once formed.

The sealing mechanism 504 and film transport belts 506 are disposed along a length of the fill tube 502 and encounter the sheet of material 700 once the sheet of material 700 has taken the shape of a cylinder. The sealing mechanism 504 may be an ultrasonic welding apparatus that engages an outer surface 512 of the material 700 at longitudinal edges 710 to join the sheet 700 at opposed portions of an inner surface 514 of the sheet 700. Namely, the sealing mechanism 504 may include a pair of wheels 516 (FIG. 10B) that are rotatable relative to the material 700, whereby the wheels 516 apply pressure to the longitudinal edges 110 at the outer surface 512 and at least one of the wheels 516 is vibrated at a predetermined frequency to direct vibratory mechanical energy toward the material 700. This energy creates frictional heat between the opposed, inner surfaces 514 of the longitudinal edges 110, thereby creating the seal 130 and joining the edges 710 together via an ultrasonic weld.

The transport belts 506 are disposed on opposite sides of the fill tube 502 and apply a force on the material 700 to draw the material 700 through the sealing mechanism 504. The transport belts 506 each include a series of rollers 518 that drive respective belts 520. The belts 520 are in contact with the outer surface 512 of the material 700 which, in turn, applies a force on the material 700 in the direction (Y) shown in FIG. 10A. Applying a force on the material 700 in the direction (Y) causes the material 700 to be drawn through the sealing mechanism 504 and the cross-sealing jaws 508.

The cross-sealing jaws 508 are disposed on opposite sides of the fill tube 502 and cooperate to seal the first end 112 and the second end 114. Namely, the cross-sealing jaws 508 are selectively drawn toward one another to seal the bag 100 at the first end 112 and at the second end 114 and, further, to separate adjacent bags 100 from one another. The cross-sealing jaws 508 seal the first end 112 and the second end 114 by applying pressure and heat to lateral edge portions 712, 712 of the sheet of material 700, thereby sealing the ends 112, 114 and ensuring the edibles 50—received from the fill tube 502 and disposed therein—remain within the bag 100 until the bag 100 is opened at either end 112, 114. The cross-sealing jaws 508 also sever the material 700 at the first end 112 and at the second end 114 once the ends 112, 114 are sealed to separate adjacent bags 100 following formation of the bags 100.

The deadfold feeding system 510 cooperates with the sealing mechanism 504 to simultaneously insert the deadfold material 150 into the seal 130 at the time of joining the longitudinal edges 110. The deadfold material 150 may include a pair of metal wires 172, 172 a that are carried by a substrate 173. The substrate 173 may be formed from a plastic material and may serve to maintain a proper spacing between the wires 172, 172 a when the wires 172, 172 a are placed between the longitudinal edges 110 of the sheet 700. While the wires 172, 172 a are described as being supported by a substrate 173, the wires 172, 172 a could alternatively be supplied without the substrate 173, as shown in FIG. 10B.

The deadfold sealing system 510 includes a cutting mechanism 522 and a spacer 524. The spacer 524 is disposed upstream from the cutting mechanism 522 and serves to separate the longitudinal edges 110 of the sheet 700 from one another to allow the wires 172, 172 a to be placed between the edges 110 and to allow the cutting mechanism 522 to extend into and between the longitudinal edges 110. Allowing the cutting mechanism 522 to extend into and between the longitudinal edges 110 allows the cutting mechanism 522 to cut the wires 172, 172 a to a desired length at the same time the wires 172, 172 a are located between the longitudinal edges 110. Accordingly, the wires 172, 172 a are inserted between opposing portions of the inner surface 514 of the sheet 700 when the longitudinal edges 110 are aligned with one another.

In operation, the deadfold material 150 is fed along the spacer 524 via a series of rollers 526. The rollers 526 cause the deadfold material 150 to be drawn between the sheet of material 700 in an area where portions of the inner surface 514 oppose one another at the longitudinal edges 110. The deadfold material 150 is cut to length by the cutting mechanism 522 just before the longitudinal edges 110 are fed though the wheels 516 of the sealing mechanism 504.

As described above, when the longitudinal edges 110 of the sheet of material 700 are fed through the wheels 516, the edges 110 are joined to one another via an ultrasonic weld. In so doing, the deadfold material 150 is encapsulated between the opposing portions of the inner surface 514 of the sheet 700 when the longitudinal edges 110 are aligned with one another. Specifically, the wheels 516 ultrasonically weld the opposed inner surfaces 514 of the sheet 700 together, thereby trapping the deadfold material 150 between the surfaces 514. The wheels 516 may include a formation that likewise creates an ultrasonic weld in the gap 174 disposed between the wires 172, 172 a such that the wires 172, 172 a are separated from one another in a direction substantially perpendicular to a longitudinal axis of each wire 172, 172 a by the material of the sheet 700.

FIGS. 6 and 7A-F illustrate a method for manufacturing the reclosable bag 100. The method 600 includes receiving 610 a rectangular sheet of material 700 that has first and second longitudinal edge portions 710 a, 710 b and first and second lateral edge portions 712 a, 712 b at 610. The rectangular sheet 700 may be made of plastic or any other material suitable for storing edibles 50 such as cereal 50 c. The method 600 includes sealing 620 the longitudinal edge portions 710 to form a tubular bag body 110 and a seal 130 along the longitudinal edge portions 710 at 620. In some examples, the seal 130 is formed by ultrasonically welding the first longitudinal edge portion 710 a with the second longitudinal edge portion 710 b. As shown in FIG. 7B, the bag body 110 has a first end 112 and a second end 114, and the seal 130 has a first layer 132 and a second layer 134.

The method 600 also includes sealing the first end 112 of the tubular body 110, while keeping the second end 114 open at 630 (FIG. 7E). The first end 112 may be sealed by ultrasonically welding a first lateral edge portion 712 a of the bag body 110. Edibles 50, such as cereal 50 c, can be placed inside the reclosable bag 100 shown in FIG. 7E once the first lateral edge portion 712 a is sealed (i.e., via the fill tube 502). Further, the reclosable bag 100 can be closed by folding the tubular bag body 110 along a deadfold length L_(D) of the deadfold material 150. In the method 600, the tubular bag body 110 is formed by sealing the longitudinal edge portions 710 of the rectangular sheet 700. In other implementations, a tubular bag body 110 may be provided and the seal 130 may not extend throughout the entire length L_(B) of the tubular bag body 110. Moreover, the method 600 includes interposing the deadfold material 150 between the first layer 132 of the seal 130 and the second layer 134 of the seal 130 at 640. The deadfold material 150 extends along a portion of the seal 130. The deadfold material 150 is positioned at least near the second end 114 of the tubular bag body 110. In the example of FIG. 7B, the deadfold material 150 includes two metal wires 172 a, 172 b. The metal wires 172 a, 172 b are separated by a gap 174. However, other arrangements may also be possible, as shown in FIGS. 5B-5E.

In some implementations, the deadfold material 150 is positioned at one of the longitudinal edge portions 710 before sealing 620 the longitudinal edge portions 710 together to form the tubular body 110 and the seal 130 along the longitudinal portions 710. This eliminates the step of interposing the deadfold material 150 between the first and second layers 132, 134 of the seal 130.

In some implementations, the first and second layers 132, 134 of the seal 130 are ultrasonically welded (as shown in FIG. 7D). By ultrasonically welding the first layer 132 and the second layer 134 of the seal 130, the deadfold material 150 is securely held between the first and second layers 132, 134 of the seal 130. Thus, an adhesive is not needed to hold the deadfold material 150 in place within the seal 130.

FIGS. 8 and 9A-9D illustrate a method 800 for manufacturing a reclosable bag 100. The method 800 includes receiving a tubular bag body 110 having a first open end 112 (having a first side and a second side 112 a and 112 b) and a second open end 114 at 810. The method 800 includes sealing the first and second sides 112 a, 12 b of the first open end 112 to form a sealed first end 112 (as shown in FIG. 9B) using an ultrasonic welding machine at 820. The second end 114 remains open at step 820 to permit the bag 100 to receive edibles 50. The method 800 also includes positioning a deadfold material 150 between the sealed first end 112 and the second open end 114 of the bag body 110 at 830. The deadfold material 150 is positioned near the second open end 114 of the bag body 110, as described above. The method 800 includes positioning a deadfold cover 156 on top of the deadfold material 150, so that the deadfold material 150 resides between the bag body 110 and the deadfold cover 156 at 840. The deadfold cover 156 is ultrasonically welded to the bag body 110 at 850. By ultrasonically welding the deadfold cover 156 to the bag body 110, the deadfold material 150 is held in place. Ultrasonic welding removes the need to use any adhesives or fasteners to attach the deadfold material 150 to the bag body 110.

As discussed above, ultrasonic welding can be used to form the seal 130 (when the bag body 110 includes two longitudinal sides 710 a, 710 b, as shown in FIGS. 7A-7E) or to attach the deadfold cover 156 to the deadfold material 150 (where the bag body 110 does not include a seal 130 housing the deadfold material 150, as shown in FIGS. 9A-9D).

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims. 

What is claimed is:
 1. A reclosable bag for storing edibles, the reclosable bag comprising: a body having an inner surface defining an inner volume that receives the edibles and an outer surface formed on an opposite side of the body than the inner surface; a seal extending substantially parallel to a longitudinal axis of the body and formed by joining a first portion of the inner surface to a second portion of the inner surface; and a deadfold material disposed in the seal between the first portion of the inner surface and the second portion of the inner surface, the deadfold material being formed from a malleable material and retained in position along the body by the seal.
 2. The reclosable bag of claim 1, wherein the deadfold material includes a first element and a second element, the first element and the second element being spaced apart from one another by a gap extending in a first direction substantially perpendicular to the longitudinal axis.
 3. The reclosable bag of claim 2, wherein the first portion of the inner surface and the second portion of the inner surface are attached to one another within the gap.
 4. The reclosable bag of claim 2, wherein the first portion of the inner surface and the second portion of the inner surface are spaced apart from one another within the gap, the first element and the second element opposing one another in the first direction within the gap.
 5. The reclosable bag of claim 2, wherein the gap is about 1 mm to about 5 mm in the first direction.
 6. The reclosable bag of claim 2, wherein the first element is formed from a metallic strip or wire and the second element is independently formed from a metallic strip or wire.
 7. The reclosable bag of claim 2, wherein the seal is formed by welding the first portion of the inner surface to the second portion of the inner surface at a first location along the first element and at a second location along the second element.
 8. The reclosable bag of claim 7, wherein the seal is formed by welding the first portion of the inner surface to the second portion of the inner surface at a third location within the gap.
 9. The reclosable bag of claim 8, wherein the first location, the second location, and the third location extend along an entire length of the first element and the second element in a direction substantially parallel to the longitudinal axis.
 10. The reclosable bag of claim 8, wherein the first portion of the inner surface and the second portion of the inner surface are ultrasonically welded to one another at the first location, the second location, and the third location.
 11. A method of manufacturing a reclosable bag comprising: forming a sheet of material having a first surface and a second surface disposed on an opposite side of the sheet of material than the first surface into a body having a substantially cylindrical shape; aligning a first longitudinal edge of the sheet with a second longitudinal edge of the sheet such that a first portion of the first surface opposes a second portion of the first surface; positioning a deadfold material between the first portion of the first surface and the second portion of the first surface; attaching the first portion of the first surface to the second portion of the first surface to retain the deadfold material between the first portion and the second portion.
 12. The method of claim 11, wherein the attaching the first portion to the second portion includes ultrasonically welding the first portion to the second portion to form a seal.
 13. The method of claim 11, wherein the positioning the deadfold material includes positioning a first element and a second element of the deadfold material between the first portion and the second portion.
 14. The method of claim 13, wherein positioning the first element and the second element includes aligning a longitudinal axis of the first element and a longitudinal axis of the second element with a longitudinal axis of the body such that all three of the axes are substantially parallel to one another.
 15. The method of claim 14, wherein attaching the first portion of the first surface to the second portion of the first surface includes attaching the first portion to the second portion at a first location along an entire length of and adjacent to the first element and at a second location along an entire length of and adjacent to the second element.
 16. The method of claim 15, wherein attaching the first portion of the first surface to the second portion of the first surface includes attaching the first portion to the second portion at a third location between the first element and the second element.
 17. The method of claim 15, wherein attaching the first portion to the second portion at the third location includes attaching the first portion to the second portion along an entire length of the first element and the second element.
 18. The method of claim 15, wherein attaching the first portion to the second portion at the first location, the second location, and the third location includes ultrasonically welding the first portion to the second portion at the first location, the second location, and the third location.
 19. The method of claim 11, wherein positioning the deadfold material between the first portion of the first surface and the second portion of the first surface includes positioning a malleable material between the first portion and the second portion.
 20. The method of claim 11, further comprising sealing a first end of the body having a substantially cylindrical shape and a second end of the body having a substantially cylindrical shape, the first end and the second end extending substantially perpendicular to the first longitudinal edge and the second longitudinal edge. 